Disposable absorbent article having doubled side flaps and backsheet strips

ABSTRACT

A disposable absorbent article includes two laterally opposing longitudinally extending backsheet strips attached to an exterior surface of an absorbent assembly in laterally opposing attachment zones. Each backsheet strip may include a water-impermeable layer and may be extensible. The absorbent assembly includes a lower covering sheet that is doubled by folding and thereby includes a first layer and a second layer. The absorbent assembly also includes laterally opposing side flaps which are formed by folding doubled portions of the lower covering sheet laterally inward. A longitudinally extending elastic gathering member is attached to each side flap adjacent to its proximal edge. When the article is worn, the elastic gathering members contract and raise the side flaps to form side barriers.

FIELD OF THE INVENTION

This invention relates to disposable absorbent articles such asdisposable diapers and other articles intended for use on incontinentpersons.

BACKGROUND OF THE INVENTION

Disposable absorbent articles are designed to absorb and contain bodilywaste in order to prevent soiling of the body and clothing of thewearer, as well as bedding or other objects with which the wearer comesinto contact.

As the usage of disposable absorbent articles has expanded, theircomplexity has increased with the incorporation of additional featuresserving to enhance their performance and appearance. The costs of thematerials and the costs of the manufacturing processes have alsoincreased in conjunction with the increase in complexity. As a result,the prices at which these articles are sold have risen to levels thatmany potential purchasers around the world cannot afford to pay. Thus, aneed exists for a simple disposable absorbent article.

SUMMARY OF THE INVENTION

A disposable absorbent article includes two laterally opposinglongitudinally extending backsheet strips attached to an exteriorsurface of an absorbent assembly in laterally opposing attachment zones.Each backsheet strip may include a water-impermeable layer and may beextensible. The absorbent assembly includes a lower covering sheet thatis doubled by folding and thereby includes a first layer and a secondlayer. The absorbent assembly also includes laterally opposing sideflaps which are formed by folding doubled portions of the lower coveringsheet laterally inward. A longitudinally extending elastic gatheringmember is attached to each side flap adjacent to its proximal edge. Whenthe article is worn, the elastic gathering members contract and raisethe side flaps to form side barriers.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawing figures, like reference numerals identifystructurally corresponding elements, which may or may not be identicalin the several exemplary embodiments that are depicted. Some of thefigures may have been simplified by the omission of selected elementsfor the purpose of more clearly showing other elements. Such omissionsof elements in some figures are not necessarily indicative of thepresence or absence of particular elements in any of the exemplaryembodiments, except as may be explicitly delineated in the correspondingwritten description.

In the drawing figures and in the written description, lowercase lettersappended to reference numerals indicate generally symmetric elements,e.g., the left and right side edges of the absorbent assembly 200 arerespectively identified by the reference numerals 237 a and 237 b. Areference numeral without an appended lowercase letter identifies all ofthe elements to which that particular reference numeral applies, e.g.,the same side edges as a group are designated 237.

FIG. 1 is a plan view of an exemplary disposable diaper 20, which isshown in its flat, uncontracted state, i.e., without the contractioninduced by elastic members. In FIG. 1, the interior portion of thediaper 20 is shown facing the viewer.

FIG. 2 is an exterior plan view of the diaper 20 of FIG. 1.

FIG. 3, FIG. 4, and FIG. 5 are section views of the diaper 20 of FIG. 1and FIG. 2 taken at the respective section lines 3-3, 4-4, and 5-5. Inthese section views, the interior portion of the diaper 20 is shownfacing upward.

FIG. 6, FIG. 7, and FIG. 8 are respectively simplified side, front, andback elevation views of the diaper 20 of FIG. 1 being worn about thelower torso of the wearer.

FIG. 9 is a plan view of an exemplary fragment of a formed web material.

FIG. 10 and FIG. 11 are simplified left and right side elevation viewsof an exemplary diaper 20 including cohesive fastening patches beingworn about a lower torso of a wearer.

FIG. 12 is a simplified plan view of another exemplary disposable diaper20, which is shown in its flat, uncontracted state and with its interiorportion facing the viewer.

FIG. 13 is a simplified exterior plan view of the diaper 20 of FIG. 12.

FIG. 14 is a perspective view of an exemplary diaper 20, which is shownin its relaxed, contracted state and with its interior portion facingupward.

FIG. 15 is a plan view of an exemplary absorbent assembly 200, shownseparately from the other portions of an exemplary diaper and with itsinterior portion facing the viewer.

FIG. 16 is a view of the absorbent assembly of FIG. 15 taken at thesection line 16-16.

FIG. 17 is a view of the absorbent assembly of FIG. 15 taken at thesection line 17-17.

FIG. 18 is a section view of an exemplary absorbent assembly 200 showingdetails of an exemplary absorbent core having particles ofsuperabsorbent material contained inside pockets

FIG. 19 is a section view of an exemplary absorbent assembly 200 havingan additional bottom sheet 226, taken at a section line corresponding tothe section line 4-4 in FIG. 1.

FIG. 20 is a plan view of another exemplary disposable diaper 20, whichis shown in its flat, uncontracted state and with its interior portionfacing the viewer.

FIG. 21 is a plan view of another exemplary disposable diaper 20, whichis shown in its flat, uncontracted state and with its interior portionfacing the viewer.

FIG. 22 is an exterior plan view of the diaper 20 of FIG. 21.

FIG. 23 is a section view of the diaper 20 of FIG. 21 and FIG. 22 takenat the section line 23-23, with its interior portion facing upward.

FIG. 24 is a plan view of another exemplary disposable diaper 20, whichis shown in its flat, uncontracted state and with its interior portionfacing the viewer.

DETAILED DESCRIPTION OF THE INVENTION

In this description, the following terms have the following meanings:

The term “absorbent article” refers to a device that absorbs andcontains liquid, and more specifically, refers to a device that isplaced against or in proximity to the body of the wearer to absorb andcontain the various exudates discharged from the body.

The term “diaper” refers to an absorbent article that is generally wornby infants and incontinent persons about the lower torso so as toencircle the waist and the legs of the wearer and that is specificallyadapted to receive and contain urinary and fecal waste.

The term “disposable” refers to the nature of absorbent articles thatgenerally are not intended to be laundered or otherwise restored orreused as an absorbent article, i.e., they are intended to be discardedafter a single use and, preferably, to be recycled, composted orotherwise disposed of in an environmentally compatible manner.

The term “longitudinal” refers to a direction running from a waist edgeto an opposing waist edge of the article and generally parallel to themaximum linear dimension of the article. Directions within 450 of thelongitudinal direction are considered to be “longitudinal”.

The term “lateral” refers to a direction running from a side edge to anopposing side edge of the article and generally at a right angle to thelongitudinal direction. Directions within 45° of the lateral directionare considered to be “lateral”.

The term “disposed” refers to an element being attached and positionedin a particular place or position in a unitary structure with otherelements.

The term “attached” refers to elements being connected or united byfastening, adhering, bonding, etc. by any method suitable for theelements being attached together and their constituent materials. Manysuitable methods for attaching elements together are well-known,including adhesive bonding, pressure bonding, thermal bonding,mechanical fastening, etc. Such attachment methods may be used to attachelements together over a particular area either continuously orintermittently.

The term “cohesive” refers to the property of a material that, once set,sticks to itself but does not to any significant degree stick to othermaterials.

The terms “water-permeable” and “water-impermeable” refer to thepenetrability of materials in the context of the intended usage ofdisposable absorbent articles. Specifically, the term “water-permeable”refers to a layer or a layered structure having pores, openings, and/orinterconnected void spaces that permit liquid water to pass through itsthickness in the absence of a forcing pressure. Conversely, the term“water-impermeable” refers to a layer or a layered structure through thethickness of which liquid water cannot pass in the absence of a forcingpressure. A layer or a layered structure that is water-impermeableaccording to this definition may be permeable to water vapor, i.e., maybe “water vapor-permeable”. Such a water vapor-permeable layer orlayered structure is commonly known in the art as “breathable”. As iswell known in the art, a common method for measuring the permeability towater of the materials typically used in absorbent articles is ahydrostatic pressure test, also called a hydrostatic head test or simplya “hydrohead” test. Suitable well known compendial methods for hydroheadtesting are approved by INDA (formerly the International Nonwovens andDisposables Association, now The Association of the Nonwoven FabricsIndustry) and EDANA (European Disposables And Nonwovens Association).

The terms “proximal” and “distal” refer respectively to the location ofan element relatively near to or far from the center of a structure,e.g., the proximal edge of a longitudinally extending element is locatednearer to the longitudinal axis than the distal edge of the same elementis located relative to the same longitudinal axis.

The terms “interior” and “exterior” refer respectively to the locationof an element that is intended to be placed against or toward the bodyof a wearer when an absorbent article is worn and the location of anelement that is intended to be placed against or toward any clothingthat is worn over the absorbent article. Synonyms for “interior” and“exterior” include, respectively, “inner” and “outer”, as well as“inside” and “outside”. Also, when the absorbent article is orientedsuch that its interior faces upward, e.g., when it is laid out inpreparation for setting the wearer on top of it, synonyms include“upper” and “lower”, “above” and “below”, “over” and “under”, and “top”and “bottom”, respectively.

Description of Exemplary Diaper Embodiments

Reference is made to FIG. 1, FIG. 2, FIG. 3, FIG. 4, FIG. 5, FIG. 6,FIG. 7, and FIG. 8 for this section of this description.

One end portion of the exemplary diaper 20 is configured as a frontwaist region 36, the longitudinally opposing end portion is configuredas a back waist region 38, and an intermediate portion is configured asa crotch region 37.

The basic structure of the diaper 20 includes an absorbent assembly 200,which has a front edge 236, a back edge 238, laterally opposing sideedges 237, an interior surface 202, and an exterior surface 204. Alongitudinal axis 42 extends through the midpoints of the front edge 236and the back edge 238 and a lateral axis 44 extends through themidpoints of the side edges 237. The absorbent assembly 200 haslaterally opposing side flaps 247 and a lower covering sheet 25 that aredescribed in more detail below.

The basic structure of the diaper 20 also includes two laterallyopposing longitudinally extending backsheet strips designated the leftbacksheet strip 100 a and the right backsheet strip 100 b. The backsheetstrips have respective front waist edges 136, back waist edges 138,proximal edges 156, interior surfaces 102, and exterior surfaces 104.Together, the two backsheet strips define the respective side edges 137of the diaper 20.

The backsheet strips 100 and the lower covering sheet 25 are attachedtogether in laterally opposing longitudinally extending attachment zonessuch as the exemplary attachment zones 220.

When the diaper 20 is worn on the lower torso of a wearer, the frontwaist edges 136 of the backsheet strips, the front edge 236 of theabsorbent assembly, the back waist edges 138 of the backsheet strips,and the back edge 238 of the absorbent assembly encircle the waist ofthe wearer, the side edges 137 encircle the legs of the wearer, thecrotch region 37 is generally positioned between the legs of the wearer,and the absorbent assembly 200 extends from the front waist region 36through the crotch region 37 to the back waist region 38.

A portion or the whole of each of the backsheet strips may be formed ofan elastically extensible material or materials. Alternatively, or inaddition, a portion or the whole of each of the backsheet strips may bemade extensible to a degree greater than the inherent extensibility ofthe material or materials from which the backsheet strip is made.Similarly, a portion of the absorbent assembly may be formed of anelastically extensible material or materials. Alternatively or inaddition, a portion of the absorbent assembly may be made extensible toa degree greater than the inherent extensibility of the material ormaterials from which the absorbent assembly is made. The additionalextensibility may be desirable in order to allow the diaper 20 toconform to the body of a wearer during movement by the wearer.Additional lateral extensibility may be particularly desirable to allowthe user of a diaper to extend the front waist region and/or the backwaist region to encircle the waist of a wearer, i.e., to tailor thewaist size and fit of a diaper to the individual wearer. Such a lateralextension of the waist region or regions may give the diaper a generallyhourglass shape and may impart a tailored appearance to the diaper whenit is worn. In addition, the additional extensibility may be desirablein order to minimize the cost of the diaper, because a relatively lesseramount of material is needed when the material is made extensible asdescribed.

For the purpose of fitting to the waist of the wearer, in someembodiments additional lateral extensibility in the absorbent assembly200 is provided only between the laterally opposing attachment zones 220where the absorbent assembly 200 and the backsheet strips 100 areattached together, rather than in the entire absorbent assembly.

Additional extensibility in the backsheet strips and/or the absorbentassembly may be provided in a variety of ways. For example, a materialor materials from which the backsheet strips and/or the absorbentassembly is/are made may be pleated by any of many known methods.Alternatively, all or a portion of the backsheet strips and/or theabsorbent assembly may be made of a formed web material or a formedlaminate of web materials like those described in U.S. Pat. No.5,518,801 issued on 21 May 1996 in the name of Chappell et al. Anexemplary fragment 300 of such a formed web material 305 is shown inFIG. 9. This formed web material 305 includes distinct laterallyextending regions 310 in which the original material has been altered byembossing or another method of deformation to create a pattern ofgenerally longitudinally oriented alternating ridges 312 and valleys314. The formed web material 305 also includes laterally extendingunaltered regions 316 located between the laterally extending alteredregions 310.

Such a formed web material 305 can be laterally extended beyond itsoriginal dimension with the application of relatively less force thanthat required to extend the same material to the same extent whenundeformed. In particular, the application of opposing divergent forcesdirected generally perpendicular to the ridges 312 and valleys 314extends such a formed web material along an axis between the opposingforces and generates a resistive contractive force, primarily in theunaltered regions 316. This resistive force is relatively smaller thanthe resistive force that is generated by the same material in itsunaltered form when extended to the same extent, at least up to anextension at which the ridges and valleys in the altered regions flattenand begin to contribute to the resistive force. Thus, such formed webmaterials exhibit an extensible behavior resembling that of traditionalelastic materials in the range of extensibility that is useful inabsorbent articles, but may be made of relatively less expensivematerials that are not inherently elastic and, thus, their use mayprovide an advantage in terms of the cost of manufacturing the absorbentarticles.

In addition, different portions of the backsheet strips and/or theabsorbent assembly may be formed to have different ranges ofextensibility and/or to be extensible to a greater or lesser degree whensubjected to a given level of opposing tensile forces, i.e., to berelatively more easily or less easily extensible. Such differentialextensibility may be desirable so that, for example, one or both of thewaist regions may be laterally extended relatively farther or relativelymore easily than the crotch region.

Description of the Backsheet Strips

The diaper 20 includes two laterally opposing longitudinally extendingbacksheet strips designated the left backsheet strip 100 a and the rightbacksheet strip 100 b as shown in FIG. 1, FIG. 2, FIG. 3, FIG. 4, andFIG. 5. The backsheet strips may be formed of a nonwoven material, forexample a synthetic nonwoven such as spunbonded or carded polyethylene,polypropylene, polyester, or rayon. Alternatively or in addition, eachbacksheet strip may include a water-impermeable layer that is formed ofa suitable material, for example a film of polyethylene or anotherpolyolefin, a microporous breathable film, a hydrophobic nonwoven, or afilm formed of coextruded polyolefin layers. For example, a suitablecoextruded film is available from Clopay Plastic Products Co. of Mason,Ohio, U.S.A. under the designation of M18-327. A multi-layer backsheetstrip, such as a laminate of a film and a nonwoven, may also be suitableand may be oriented with the nonwoven disposed exteriorly to provide thefeel and appearance of a cloth-like outermost layer, with the nonwovendisposed interiorly to separate the film from the skin of the wearer, orwith nonwovens disposed both exteriorly and interiorly.

The front waist region and the back waist region can be fastenedtogether in many ways to form a waist opening and two leg openingssuitable for encircling the waist and the legs of the wearer. Forexample, separate fastening devices such as safety pins, separate tapes,a separate tie strap or straps, and/or a separate belt can be used forthis purpose. Alternatively or in addition, fastening elements can beincorporated into the disposable absorbent article to enable a user toapply the diaper to the body of the wearer without, or in conjunctionwith, any separate fastening devices. Many suitable types of suchincorporated fastening elements are well-known, including, for example,tapes, adhesives, adhesive tape tabs, ties, buttons, hooks, loops, snapfasteners, other forms of mechanical fasteners, cohesive patches, etc.Some suitable mechanical fasteners may be adapted to engage with anonwoven, e.g., a nonwoven layer of a laminate backsheet or the lowercovering sheet.

The fastening of the front waist region and the back waist regiontogether may be openable and refastenable to allow for the adjustment ofthe fit of the diaper on the wearer and for the inspection of theinterior of the diaper without fully removing it from the wearer.Alternatively, the fastening may be permanent, i.e., its opening mayrequire the destruction of a portion of the diaper, e.g., the tearing ofa portion of the diaper or the breaking of fused side seams.

Cohesive fastening patches may be formed by the application of acohesive material onto a substrate. The cohesive material may be appliedin any of a variety of patterns, such as a continuous film, discretedots, stripes, polygons, etc., and/or spaced and interconnectedgeometric elements describing a grid. Suitable synthetic cohesiveproducts are available from Andover Coated Products, Incorporated, ofSalisbury, Mass., U.S.A. and are described in U.S. Pat. No. 6,156,424issued on 5 Dec. 2000 in the name of Taylor.

In FIG. 1, FIG. 2, FIG. 3, FIG. 5, FIG. 10, and FIG. 11, cohesivefastening patches 110 a and 110 b are shown disposed on the exteriorsurfaces of the respective backsheet strips 100 a and 100 b in the frontwaist region 36. In this exemplary embodiment, functionallycomplementary cohesive fastening patches 120 a and 120 b are disposed onthe interior surfaces of the respective backsheet strips 100 a and 100 bin the back waist region 38. When the diaper 20 is worn as shown in FIG.10 and FIG. 11, the cohesive fastening patches on the interior overlapthe cohesive fastening patches on the exterior and the cohesion of theoverlapped cohesive fastening patches fastens the front waist region 36and the back waist region 38 together at the sides of the diaper 20. Theconfiguration shown in these figures is adapted for back-over-frontfastening.

Alternatively, the front cohesive fastening patches may be disposed onthe interior of the diaper 20 and the back cohesive fastening patchesmay be disposed on the exterior of the diaper 20 in order to adapt theconfiguration for front-over-back fastening. Alternatively, the cohesivefastening patches may be disposed in a reversible configuration that isadapted to provide the user of the diaper with both options forfastening, i.e., either back-over-front or front-over-back, according topersonal preference. For example, cohesive fastening patches that aredisposed on both the exterior and the interior of the diaper 20 mayallow a back cohesive fastening patch to overlap a front cohesivefastening patch or the front cohesive fastening patch to overlap theback cohesive fastening patch.

When the underlying portion of the diaper is extensible, it ispreferable that the cohesive fastening patches be similarly extensiblesuch that the underlying extensible portion of the diaper is notrestrained.

Alternatively, adhesive tape tabs may be attached to the diaper 20 andmay be used to fasten the back waist region 38 and the front waistregion 36 together. For example, as shown in FIG. 12 and FIG. 13,laterally opposing adhesive tape tabs 114 a and 114 b may be attached tothe respective backsheet strips 100 a and 100 b at or adjacent to theside edges 137 a and 137 b of the diaper 20. Suitable adhesive tapes areavailable from the 3M Corporation of St. Paul, Minn., U.S.A., under thedesignation of XMF99121, and from the Avery Dennison Corporation,Specialty Tape Division, Mentor, Ohio, U.S.A., under the designation ofF4416.

Optionally, fastening sheets may also be attached to the diaper 20 andused in conjunction with such adhesive tape tabs. For example, fasteningsheets 116 may be attached onto the exterior surfaces 104 of therespective backsheet strips 100 and/or the absorbent assembly 200 asshown in FIG. 13. When a fastening sheet is provided, the adhesive tapetabs may be adhered to the fastening sheet to fasten the back waistregion 38 and the front waist region 36 together. The fastening sheetserves to distribute the tensile force transmitted by each of theadhesive tape tabs over an area larger than the adhered area of theadhesive tape tab and may, itself, bear a portion of the tensile forceand thereby relieve a portion of the force exerted on the underlyingportion of the diaper, such as the backsheet strips. Thus, for example,the incorporation of such a fastening sheet may make it possible to usea relatively inexpensive and relatively weak material for the underlyingportion of the diaper. When mechanical fasteners are used instead ofadhesive tape tabs, a fastening sheet can have a surface and/or elementsthat engage with the mechanical fastener, e.g., loops with which hooksmay engage. When the underlying portion of the diaper is extensible, itis preferable that the fastening sheet be similarly extensible such thatthe underlying extensible portion of the diaper is not restrained.

Description of the Absorbent Assembly

As shown in FIG. 1, FIG. 2, FIG. 3, FIG. 4, and FIG. 5, the absorbentassembly 200 has laterally opposing side flaps 247 formed by foldingportions of the absorbent assembly toward the longitudinal axis 42, toform both the respective side flaps 247 and the side edges 237 of theabsorbent assembly 200. The absorbent assembly 200 may simply be foldedloosely or may be creased along a portion of each of its side edges 237.For example, it may be desirable to form creases along portions of theside edges 237 in the crotch region 37 in order to impart a morefinished appearance to the diaper 20. Alternatively or in addition tocreasing, a portion of each of the folded side flaps 247 adjacent to theside edges 237 may be attached to the interior surface 202 of theabsorbent assembly 200 to achieve a similar result. The side flaps mayoverlap the absorbent core 250, i.e., the proximal edges 255 of the sideflaps may lie laterally inward of the respective side edges 257 of theabsorbent core 250. Alternatively, the side flaps may not overlap theabsorbent core.

In the exemplary diaper 20 shown in FIG. 1, the absorbent assembly 200extends the full length of the backsheet strips 100 between the frontwaist edges 136 and the back waist edges 138. Such a full lengthconfiguration may be desirable in order to minimize the amount of wastematerial and the difficulty associated with the manufacture of thediaper 20, especially when the method used to manufacture the diaper 20requires the introduction of the material or materials for the absorbentassembly 200 in the form of a continuous web or multiple continuouswebs. Also, such a full length configuration may be desirable in orderto isolate the skin of the wearer from the backsheet strips.Alternatively, the absorbent assembly 200 may be shorter and extend lessthan the full length of the backsheet strips. Such a shorterconfiguration may be desirable in order to minimize the total amount ofmaterial used and the cost of the diaper 20. As another alternative, theabsorbent assembly 200 may extend longitudinally beyond the backsheetstrips. Such a longer configuration may be desirable in order tominimize the total amount of material used in the backsheet strips andtherefore the cost of the diaper 20.

Each of the side flaps 247 is attached to the interior surface 202 ofthe absorbent assembly 200 in attachment zones located at or adjacent tothe front edge 236 and the back edge 238. For example, in the diaper 20shown in FIG. 2, the left side flap 247 a is attached to the interiorsurface 202 of the absorbent assembly 200 in attachment zones 251 a and251 c, while the right side flap 247 b is attached to the interiorsurface 202 in attachment zones 251 b and 251 d. The attachment zonesmay have equal areas or may be unequal in area.

Between the attachment zones, the proximal edges 255 of the side flaps247 remain free, i.e., are not attached to the interior surface 202 ofthe absorbent assembly 200. Also between the attachment zones, each sideflap preferably includes a longitudinally extensible flap elastic memberthat is attached adjacent to the proximal edge of the side flap. Forexample, in the diaper 20 shown in FIG. 1, elastic strands 267 areattached adjacent to the respective proximal edge 255 of the side flaps.The flap elastic member may be sandwiched between two layers of theabsorbent assembly or may be attached on a surface of the absorbentassembly and remain exposed.

When stretched, the flap elastic members allow the proximal edges of theside flaps to extend to the flat uncontracted length of the absorbentassembly, as shown in FIG. 1. When allowed to relax, the flap elasticmembers contract to gather the portions of the proximal edges alongwhich the flap elastic members are attached. For example, when theexemplary diaper 20 is in a relaxed condition as shown in FIG. 14, theelastic strands 267 contract to gather the proximal edges 255 of theside flaps 247. The contractive forces of the elastic strands pull thefront waist region 36 and the back waist region 38 toward each other andthereby bend the absorbent assembly 200 and the entire diaper 20 into a“U” shape in which the interior of the “U” shape is formed by theinterior portions of the diaper. Because the proximal edges remain freebetween the attachment zones, the contractive forces of the elasticstrands lift the proximal edges 255 of the side flaps 247 away from theinterior surface 202 of the absorbent assembly and thereby raise theside flaps into position to serve as side barriers. The lateral spacingof the lifted proximal edges is selected to allow the deposit of bodilywastes from the lower torso of the wearer into the space between theraised side flaps. The width of each of the side flaps 247 in effectbecomes its height when the free portion of its proximal edge is liftedand the side flap is raised. This height preferably is selected to allowthe lifted proximal edges 255 to fit into the leg creases of the body ofthe wearer to form seals to help prevent the leakage of deposited bodilywaste out of the diaper.

As shown in FIG. 15, FIG. 16, and FIG. 17, the absorbent assembly 200includes an absorbent core 250 that serves to absorb and retain liquidbodily waste materials. The absorbent core 250 has a front edge 256, aback edge 258, laterally opposing side edges 257, an interior surface252, and an exterior surface 254.

The absorbent assembly 200 may include an upper covering sheet disposedabove the absorbent core 250 in addition to a lower covering sheet isdisposed below the absorbent core 250. If both are present, such anupper covering sheet and lower covering sheet may be attached togetherto contain the absorbent core 250 between them and thereby form theabsorbent assembly 200. For example, in the exemplary absorbent assembly200 shown in FIG. 15, FIG. 16, and FIG. 17, an upper covering sheet 24and a lower covering sheet 25 are attached together in the laterallyopposing attachment zones 29.

An upper covering sheet, if present, is water-permeable and allowsliquid bodily waste to pass through its thickness to the absorbent core.The upper covering sheet preferably is formed of a soft material thatwill not irritate the skin of the wearer, for example a syntheticnonwoven such as spunbonded or carded polyethylene, polypropylene,polyester, or rayon.

The lower covering sheet 25 is doubled by folding and thereby includes afirst layer 27 and a second layer 28 at least in the side flaps 247,i.e., at least between each side edge 237 and the respective proximaledge 255 of the side flap 247, both layers 27 and 28 are present, whilebetween the side edges 237 below the absorbent core 250, only one of thelayers 27 and 28 needs to be present. In some exemplary embodiments,both the first layer 27 and the second layer 28 are present oversubstantially the entire area of the lower covering sheet 25. In both ofthese variations of the structure, the side flap elastic members 267 aresandwiched between the first layer 27 and the second layer 28 adjacentto the proximal edges 255 of the side flaps 247. Doubling by folding isa particularly easy and cost-effective way of processing sheet materialsin a manufacturing system, in part because it obviates the need toprecisely align the edges of separate sheets when forming a doubledstructure. In addition, doubling by folding makes it unnecessary toattach the doubled layers together, at least at the fold, although thelayers can be attached together wherever desired for certain purposes,as explained below.

The proximal edge 255 of at least one of the side flaps 247 is formedwhere the lower covering sheet 25 is folded for doubling. For example,in the exemplary embodiment shown in FIG. 1, FIG. 2, FIG. 3, FIG. 4, andFIG. 5, both of the proximal edges 255 of the side flaps 247 are formedby the folding of the lower covering sheet 25 for doubling. In thisembodiment, the lower covering sheet 25 is folded twice to form the twoproximal edges 255 and the layers 27 and 28 are overlapped and attachedtogether adjacent to the original longitudinally extending edges 33 ofthe lower covering sheet 25 in the longitudinally extending attachmentzone 35 disposed below the absorbent core 250. Alternatively, theattachment zone 35 may be disposed laterally differently from thelocation shown in these figures. For example, the attachment zone 35 maybe disposed adjacent to one of the side edges 237 of the absorbentassembly 200 or may be disposed between one of the proximal edges 255 ofone of the side flaps 247 and the respective side edge 237. As anotherexample, the lower covering sheet 25 may be folded only once at theproximal edge 255 of one of the side flaps 247 and the attachment zone35 where the layers 27 and 28 are attached together may be disposedadjacent to the proximal edge 255 of the laterally opposing side flap247 such that the original longitudinally extending edges 33 are exposedthere. As an alternative to overlapping the original longitudinallyextending edges 33, the original edges 33 may be laterally spaced andthe lower covering sheet 25 may be attached in two laterally spacedattachment zones 35 adjacent to the two original edges 33 to one otherstructural element, such as the absorbent core 250, or to two otherstructural elements, such as the backsheet strips 100.

The layers 27 and 28 of the doubled lower covering sheet 25 may remainunattached to each other and thus free to contact each other or separatefrom each other. Alternatively, the layers of the doubled lower coveringsheet 25 may be attached together laterally continuously orintermittently between the proximal edges 255 of the side flaps 247 andthe side edges 237 of the absorbent assembly 200. Alternatively, or inaddition, the layers of the doubled lower covering sheet 25 may beattached together laterally continuously or intermittently below theabsorbent core 250 between the side edges 237 of the absorbent assembly200. For example, the layers of the doubled lower covering sheet 25 maybe attached together by adhesives, mechanical bonds, or thermal bonds,or by a combination of known bonding methods.

In the exemplary embodiment shown in FIG. 1, FIG. 2, and FIG. 4, thelayers 27 and 28 are attached together in laterally spaced attachmentzones 260 extending longitudinally through the crotch region 37 and intothe waist regions 36 and 38. Such longitudinally extending attachmenttogether prevents the layers from separating and thereby presenting anundesirable baggy or blousy appearance around the legs of the wearer, aswell as tending to stiffen the side flaps 247 slightly and therebyhelping to ensure their proper fit against the body.

Alternatively, or in addition, the layers 27 and 28 of the doubled lowercovering sheet 25 may be attached together in the waist regions 36 and38 adjacent to the front and back edges 236 and 238 of the absorbentassembly 200, for example in laterally extending attachment zones 259 asshown in FIG. 1, FIG. 3, and FIG. 5. This lateral attachment may belaterally intermittent or laterally continuous. When such laterallyextending attachment is continuous, it prevents the layers fromseparating and thereby presenting an undesirable unfinished appearanceat the waist edges, as well as forming a barrier serving to prevent theleakage of any liquid waste from between the layers at the front and/orback edge of the absorbent assembly.

Exemplary materials suitable for use in the doubled lower covering sheet25 include breathable polyolefinic films, microporous or otherbreathable formed films, breathable monolithic films, and hydrophobicnonwovens. Suitable hydrophobic nonwovens include SM (spunbondmeltblown), SMS (spunbond meltblown spunbond), and SMMS (spunbondmeltblown meltblown spunbond) composites. The materials of the watervapor-permeable side sheets may be selected to balance overall producteconomics and function. For example, a relatively inexpensive nonwovenhaving a relatively low basis weight may provide the requisite level ofwater-impermeability when it is doubled, and its relatively low cost mayoffset the cost associated with the use of a greater amount of materialthan would be used in a single-layer lower covering sheet made of arelatively more expensive nonwoven material.

The absorbent assembly and the backsheet strips may be attached togetherover any part or the whole of the length of the absorbent assembly.Preferably, the second layer 28 of the lower covering sheet 25 isattached to the backsheet strips in laterally opposing longitudinallyextending attachment zones such as the exemplary attachment zones 220shown in FIG. 2, FIG. 3, FIG. 4, FIG. 5, FIG. 13, and FIG. 19. Theportions of the backsheet strips that lie outside such an attachmentpattern are not restrained by attachment to the absorbent assembly andtherefore remain extensible. For example, a relatively narrowlongitudinally extending attachment zone 220 leaves the majority of thewidth of the respective backsheet strip 100 freely extensible andthereby allows extension of that backsheet strip 100 in the lateraldirection.

Within the extent of the attachment zones, the absorbent assembly may beattached to the backsheet strips continuously or intermittently. Forexample, a film of an adhesive may be applied continuously over theentire area of the attachment zones and then used to continuously attachthe absorbent assembly to the backsheet strips. As an alternativeexample, an adhesive may be applied discontinuously at and inside theboundaries of the attachment zones, such as in the form of dots,stripes, beads, spirals, etc., and then used to attach the absorbentassembly to the backsheet strips.

The absorbent core 250 may be attached to the first layer 27 of thelower covering sheet 25 over any part or the whole of the area of theabsorbent core. Preferably, the absorbent core is attached on itsexterior surface to the lower covering sheet in a cruciform attachmentpattern, i.e., in an attachment pattern that forms or is arranged in across or “+” shape. The cruciform attachment pattern may be contiguous,i.e., all of its portions may be touching or connected throughout thepattern in an unbroken sequence, or may include detached portions andthereby lack contiguity but still be arranged such that the shape of theoverall pattern is a cruciform. An exemplary contiguous cruciformattachment pattern 210 is shown in FIG. 15, FIG. 16, and FIG. 17.Suitable configurations of cruciform attachment patterns are disclosedin U.S. patent application Ser. No. 10/880,128 filed on 29 Jun. 2004.

When an adhesive is used for the attachment, less may be necessary in acruciform attachment pattern than in a more extensive attachmentpattern. In addition, the portions of the lower covering sheet that lieoutside such a cruciform attachment pattern are not restrained byattachment to the absorbent core and therefore can be extensible. Inparticular, a relatively narrow longitudinally extending portion 212 ofa cruciform attachment pattern 210 like that shown in FIG. 15 and FIG.17 leaves the majority of the width of the lower covering sheet 25 inthe front waist region 36 and in the back waist region 38 unrestrainedby the absorbent core 250 and thereby allows extension of the lowercovering sheet 25 in the lateral direction in these regions. Arelatively wide laterally extending portion 214 of a cruciformattachment pattern 210 like that shown in FIG. 15 and FIG. 16 preventsthe portion of the lower covering sheet 25 in the crotch region 37 towhich the absorbent core 250 is attached from shifting relative to theabsorbent core 250 in that region and thereby contributes to theeffectiveness of the raised side flaps. For example, if the lowercovering sheet in the crotch region 37 were free to shift laterally, theraised side flaps 247 might distort and fail to maintain contact withthe body or become improperly positioned.

Within the extent of the cruciform attachment pattern, the absorbentcore may be attached to the lower covering sheet continuously orintermittently. For example, a film of an adhesive may be appliedcontinuously over the entire area of the cruciform attachment patternand then used to continuously attach the absorbent core to the lowercovering sheet. As an alternative example, an adhesive may be applieddiscontinuously at and inside the boundaries of the cruciform attachmentpattern, such as in the form of dots, stripes, beads, spirals, etc., andthen used to attach the absorbent core to the lower covering sheet.

The absorbent core 250 includes a storage component 272 that serves toabsorb and retain liquid bodily waste materials. Suitable knownmaterials for the absorbent core storage component include cellulosefibers in the form of comminuted wood pulp, which is commonly known as“airfelt”, layers or sheets of a natural or synthetic fibrous materialor materials, a superabsorbent polymer or polymers, etc. These absorbentmaterials may be used separately or in combination. Many known absorbentmaterials may be used in a discrete form, i.e., in the form of fibers,granules, particles, layers and the like. Such a discrete form of anabsorbent material may be immobilized by an adhesive that attaches thediscrete pieces together to form a coherent layer or that attaches thediscrete pieces to a substrate layer or that attaches the discretepieces both to each other and to the substrate layer.

The absorbent core may include an acquisition component in addition toone or more storage components. The absorbent core acquisition componentserves to acquire deposited liquid bodily waste material and transfer itto the absorbent core storage component. Any porous absorbent materialwhich will imbibe and partition liquid bodily waste material to thestorage component or components may be used to form the acquisitioncomponent. Preferred materials for the acquisition component includesynthetic fiber materials, open celled polymeric foam materials, fibrousnonwoven materials, cellulosic nonwoven materials, and variouscombination synthetic/cellulosic nonwoven materials. For example, theacquisition component may be formed of a nonwoven web or webs ofsynthetic fibers including polyester, polypropylene, and/orpolyethylene, natural fibers including cotton and/or cellulose, blendsof such fibers, or any equivalent materials or combinations ofmaterials. Examples of such acquisition materialsare more fullydescribed in U.S. Pat. No. 4,950,264 issued to Osborn on Aug. 21, 1990.High loft nonwoven acquisition materials suitable for the acquisitioncomponent of the present invention can be obtained from Polymer Group,Inc., (PGI), 450 N.E. Blvd, Landisville, N.J. 08326, U.S.A., under thematerial code designation of 98920.

Such an absorbent core acquisition component 290 is shown overlying theabsorbent core storage component 272 in FIG. 15, FIG. 16, and FIG. 17. Aseparation sheet 292 of, e.g., a tissue or a nonwoven material, may bedisposed between the absorbent core storage component 272 and theabsorbent core acquisition component 290 to help ensure that none of thegel formed by a superabsorbent polymer reaches the skin of the wearer.This separation sheet 292 may extend laterally beyond the side edges 257of the absorbent core 250 and the upper covering sheet 24 may beattached to the separation sheet 292. In this arrangement, the liquidbodily waste material that is deposited onto the upper covering sheet 24will pass through the thickness of the upper covering sheet 24 to beabsorbed by the absorbent core acquisition component 290, and some orall of it may then pass through the thickness of the separation sheet292 and then be absorbed and retained by the absorbent core storagecomponent 272.

As shown in FIG. 18, in some exemplary embodiments, an absorbent corestorage component 272 may include the discrete form of an absorbentmaterial that is immobilized in pockets formed by a layer of athermoplastic material, such as a hot melt adhesive, that intermittentlycontacts and adheres to a substrate sheet, while diverging away from thesubstrate sheet at the pockets. Absorbent core components having suchstructures and being suitable for the storage of liquid bodily wastesare described in co-pending and commonly assigned U.S. patentapplications Ser. Nos. 10/776,839 and 10/776,851, both filed on 11 Feb.2004. An exemplary absorbent core storage component 272 having such astructure is shown in FIG. 18. In this absorbent core storage component272, particles 270 of a superabsorbent polymer are contained insidepockets 280 formed by a layer 275 of a thermoplastic material. Theabsorbent core storage component may include both particles of asuperabsorbent polymer and airfelt and both materials may be containedinside the pockets formed by the layer of the thermoplastic material.Alternatively, as shown in FIG. 18, an exemplary absorbent core storagecomponent may contain no airfelt and therefore the component can be maderelatively thinner and more flexible for the comfort of the wearer. Inaddition, the particles of the superabsorbent polymer can be immobilizedrelatively more easily in the absence of airfelt. As shown in FIG. 18,the layer 275 of the thermoplastic material intermittently contacts andadheres to a substrate sheet 274 at the areas of attachment 282. Betweenthe areas of attachment 282, the layer 275 diverges away from thesubstrate sheet 274 to form the pockets 280. The layer 275 may have theform of a sheet of fibers of the thermoplastic material through whichthe liquid bodily waste may pass to be absorbed by the particles 270 ofthe superabsorbent polymer.

In FIG. 18, a separate thermoplastic layer covering sheet 276 is shownoverlying the layer 275 of the thermoplastic material. Alternatively,the separate thermoplastic layer covering sheet 276 may be omitted. Asanother alternative, two absorbent core storage components each likethat shown in FIG. 18 except for the omission of the thermoplastic layercovering sheet 276 may be superposed with one absorbent core storagecomponent inverted such that the respective substrate sheets distallyoppose each other. In such a combination of absorbent core storagecomponents, an uppermost substrate sheet may serve as an upper coveringsheet.

The absorbent assembly may include an additional bottom sheet to enhancethe protection against leakage. Such an additional bottom sheet may bewater-impermeable and may be formed of a suitable material, for examplea film of polyethylene or another polyolefin, a microporous breathablefilm, a hydrophobic nonwoven, or a film formed of coextruded layers ofpolyolefin layers. For example, a suitable coextruded film is availablefrom Clopay Plastic Products Co. of Mason, Ohio, U.S.A. under thedesignation of M18-327. For example, as shown in FIG. 19, an additionalbottom sheet 226 may be disposed below the absorbent core 250 betweenthe layers 27 and 28 of lower covering sheet 25. Alternatively, theadditional bottom sheet may be attached to the absorbent assembly eitherinteriorly or exteriorly of the lower covering sheet. This additionalbottom sheet may extend laterally less far than either of the side edges237 of the absorbent assembly 200, as shown in FIG. 19, or may extendlaterally to overlap one or both of the side edges.

When such an additional bottom sheet is attached inside the absorbentassembly between the lower covering sheet and the absorbent core, theadditional bottom sheet may be attached to the lower covering sheet in acruciform attachment pattern similar to that shown in FIG. 15, thusleaving the portions of the lower covering sheet that lie outside thecruciform attachment pattern unrestrained by attachment to theadditional bottom sheet and allowing these portions to be extensible.

Alternatively or in addition, the additional bottom sheet in such anembodiment may be attached in such a cruciform attachment pattern to theabsorbent core, thus leaving the portions of the additional bottom sheetthat lie outside the cruciform attachment pattern unrestrained byattachment to the absorbent core and therefore allowing these portionsto be extensible. In such an embodiment, even if the additional bottomsheet is attached to the lower covering sheet in a pattern other than acruciform, the lower covering sheet is not indirectly restrained by theabsorbent core and therefore is allowed to be extensible.

Description of the Shape of the Article

The finished diaper may have a generally rectangular shape, as in theexemplary diaper 20 shown in FIG. 1 and FIG. 2. Such a generallyrectangular configuration may be desirable in order to minimize theamount of waste material and the difficulty associated with themanufacture of the diaper 20. Alternatively, the diaper may have sideedges 137 that are not straight, but instead are curved and/or notched,thereby giving an overall shape in plan view of an hourglass or of an“I” to the diaper 20. Such a non-rectangular configuration may bedesirable in order to impart a tailored appearance to the diaper 20 whenit is worn. Such a non-rectangular configuration may also be desirablein order to impart an impression that the diaper 20 will fit comfortablybetween the legs of a wearer.

A non-rectangular configuration of the diaper may be formed in any oneof several ways. For example, laterally distal portions may be removedfrom the diaper to make its lateral dimension at and adjacent to thelateral axis 44 smaller than its lateral dimension at and adjacent tothe front waist edge 136 and smaller than its lateral dimension at andadjacent to the back waist edge 138, i.e., to make the diaper narrowerin the crotch region 37 than at the waist edges. An exemplary form ofsuch a non-rectangular configuration of the diaper is shown in FIG. 20.As shown in this figure, portions of the backsheet strips 100 may beremoved to form laterally opposing side notches 111, while leaving thebacksheet strips longitudinally continuous.

Alternatively, a portion of each of the backsheet strips 100 may befolded laterally inward in order to form a non-rectangular configurationof the diaper. For example, as shown in FIG. 21, FIG. 22, and FIG. 23,laterally opposing portions 107 of the backsheet strips 100 in thecrotch region 37 may be folded laterally inward to overlap therespective side flaps 247 and may be attached to the side flaps, forexample, in the respective attachment zones 109. Preferably, each of thefolded laterally opposing portions 107 extends laterally only a part ofthe way from the respective side edge 237 of the absorbent assembly 200toward the longitudinal axis 42, thus leaving uncovered respectiveexposed portions 207 of the side flaps, which form breathable sidebarriers when the diaper is worn, as described above.

As another alternative, the backsheet strips may be made longitudinallydiscontinuous in order to form a non-rectangular configuration of thediaper. For example, as shown in FIG. 24, the backsheet strips may beseparated into a left front backsheet strip 100 a, a left back backsheetstrip 100 c, a right front backsheet strip 100 b, and a right backbacksheet strip 100 d, and each of these backsheet strips may extendlaterally beyond the side edges 237 of the absorbent assembly 200,thereby imparting an “I” shape to the diaper 20.

Statements of Incorporation by Reference and Intended Scope of Claims

The disclosures of all patents, patent applications and any patentswhich issue thereon, as well as any corresponding published foreignpatent applications, and all publications listed and/or referenced inthis description, are hereby incorporated in their entireties herein byreference. It is expressly not admitted that any of the documents or anycombination of the documents incorporated herein by reference teaches ordiscloses the present invention.

While particular embodiments and/or individual features of the presentinvention have been illustrated and described, it would be obvious tothose skilled in the art that various other changes and modificationscan be made without departing from the spirit and scope of theinvention. Further, it should be apparent that all combinations of suchembodiments and features are possible and can result in preferredexecutions of the invention. Therefore, the following claims areintended to cover all such changes and modifications that are within thescope of this invention.

1. A disposable diaper having a front waist region, a back waist region,a crotch region between the waist regions, a longitudinal axis, and alateral axis, and comprising: an absorbent assembly comprising anabsorbent core, a lower covering sheet, a front edge, a back edge,laterally opposing side edges extending between the front edge and theback edge, an exterior surface, and an interior surface; whereinlaterally opposing longitudinally extending portions of the lowercovering sheet are folded interiorly laterally inward to form the sideedges of the absorbent assembly and laterally opposing side flaps havingproximal edges, the lower covering sheet being doubled by folding andthereby having first and second layers for at least a portion of thedistance between each of the proximal edges and the respective sideedges; wherein each of the side flaps are attached adjacent to itslongitudinally distal ends to the interior surface and wherein each ofthe side flaps have a longitudinally extending elastic gathering membersandwiched between the first and second layers adjacent to its proximaledge; and two laterally opposing longitudinally extending backsheetstrips attached to the exterior surface of the lower covering sheet. 2.The disposable diaper of claim 1 wherein the doubled lower coveringsheet is water-impermeable.
 3. The disposable diaper of claim 2 whereinthe lower covering sheet is formed of a hydrophobic nonwoven material.4. The disposable diaper of claim 1 wherein the absorbent assemblyfurther comprises an additional bottom sheet disposed between the firstlayer and the second layer of the doubled lower covering sheet.
 5. Thedisposable diaper of claim 4 wherein the additional bottom sheet iswater-impermeable.
 6. The disposable diaper of claim 5 wherein theadditional bottom sheet is water vapor-permeable.
 7. The disposablediaper of claim 1 wherein the elastic gathering member is sandwichedbetween the first layer and the second layer of the doubled lowercovering sheet.
 8. The disposable diaper of claim 1 wherein the proximaledges of both of the side flaps are formed by the folding of the lowercovering sheet for doubling.
 9. The disposable diaper of claim 1 whereinthe doubled lower covering sheet has the first and second layers oversubstantially its entire area.
 10. The disposable diaper of claim 9wherein the lower covering sheet has two original longitudinallyextending edges and the first layer and the second layer are overlappedand attached together adjacent to the original edges.
 11. The disposablediaper of claim 1 wherein the first layer and the second layer areattached together in laterally spaced longitudinally extendingattachment zones.
 12. The disposable diaper of claim 11 wherein thelaterally spaced longitudinally extending attachment zones are disposedbetween the proximal edges of the side flaps and the respective sideedges of the absorbent assembly.
 13. The disposable diaper of claim 11wherein the laterally spaced longitudinally extending attachment zonesare disposed below the absorbent core between the side edges of theabsorbent assembly.
 14. The disposable diaper of claim 1 wherein thefirst layer and the second layer are attached together in laterallyextending attachment zones adjacent to the front edge and the back edgeof the absorbent assembly.
 15. The disposable diaper of claim 14 whereinthe laterally extending attachment zones are laterally continuous. 16.The disposable diaper of claim 1 wherein when allowed the elasticgathering member is allowed to relax, the elastic gathering membercontracts and lifts the proximal edge away from the interior surface ofthe absorbent assembly, thereby raising the side flap to form a sidebarrier.
 17. A disposable diaper having a front waist region, a backwaist region, a crotch region between the waist regions, a longitudinalaxis, and a lateral axis, and comprising: an absorbent assemblycomprising an absorbent core, a lower covering sheet, a front edge, aback edge, laterally opposing side edges extending between the frontedge and the back edge, an exterior surface, and an interior surface;wherein the absorbent core is attached to the lower covering sheet viaan attachment pattern comprising a longitudinally extending portiondisposed along the longitudinal axis and at least one laterally distalportion; wherein laterally opposing longitudinally extending portions ofthe lower covering sheet are folded interiorly laterally inward to formthe side edges of the absorbent assembly and laterally opposing sideflaps having proximal edges, the lower covering sheet being doubled byfolding and thereby having first and second layers for at least aportion of the distance between each of the proximal edges and therespective side edges, and two laterally opposing longitudinallyextending backsheet strips attached to the exterior surface of the lowercovering sheet.
 18. The disposable diaper of claim 17 wherein at least aportion of the lower covering sheet lying outside the cruciform patternis laterally extensible.
 19. A disposable diaper having a front waistregion, a back waist region, a crotch region between the waist regions,a longitudinal axis, and a lateral axis, and comprising: an absorbentassembly comprising an absorbent core, a lower covering sheet, a frontedge, a back edge, laterally opposing side edges extending between thefront edge and the back edge, an exterior surface, and an interiorsurface; wherein laterally opposing longitudinally extending portions ofthe lower covering sheet are folded interiorly laterally inward to formthe side edges of the absorbent assembly and laterally opposing sideflaps having proximal edges, the lower covering sheet being doubled byfolding and thereby having first and second layers for at least aportion of the distance between each of the proximal edges and therespective side edges; and two laterally opposing longitudinallyextending backsheet strips attached to the exterior surface of the lowercovering sheet, each of the backsheet strips having at least onefastening element attached to it, the fastening element being adaptedfor fastening the front waist region and the back waist region togetherto encircle a waist and a leg of a wearer.
 20. The disposable diaper ofclaim 19 wherein the fastening element includes a cohesive fasteningpatch.
 21. A disposable diaper comprising: a sheet comprising and aninterior surface and an exterior surface and forming multiple componentsof the diaper, including a front waist region, a back waist region, acrotch region between the front and back waist regions, a backsheet, andbarrier leg cuffs; an absorbent assembly attached directly to theinterior surface of the sheet; wherein the sheet is folded over alongfirst and second laterally opposing side edges, respectively, to formfirst and second laterally opposing side flaps, the first and secondside flaps each comprising a distal folded edge running longitudinallyand an opposing proximal free edge running longitudinally, wherein theinterior surfaces of the sheet are directly bonded together in the fontand back waist regions of the first and second laterally opposing sideflaps, wherein the first and second proximal free edges of the first andsecond side flaps, respectively, are folded over to contain first andsecond longitudinally extending elastic gathering members, respectively,wherein the elastic gathering members are attached directly to theinterior surface of the sheet such that the sheet gathers and formsbarrier leg cuffs, and wherein a substantial portion of the sheet isextensible; a backsheet strip attached to the exterior surface of thesheet along each of the laterally running distal folded edges of theside flaps; and one or more fasteners attached to the backsheet strips.